Catalytic reaction apparatus



July 12, 1949.

FIG.

' L. W. T. CUMMINGS CATALYTIC REACTION APPARATUS -Filed Oct. 13, 1947 3 Sheets-Sheet 1 INVENTOR. LELAND W.T. CUMMINGS ATTORNEYS July 12, 1949.

Filed Oct. 13, 1947 FIG-2 L. W. T. CUMMINGS CATALYTIC REACTION APPARATUS 3 Sheets-Sheet 2 LELAND W. T. cummm es ATTORNEYS y 1949, L. w. T. CUMMINGS 2,475,822

CATALYTIC REACTION APPARATUS Filed 001;. 15, 1947 3 Sheets-Sheet 3 F/G.8 /3-e INVENTOR. LELAND w..T. CUMMINGS ATTORNEYS Patented July 12, 1949 CATALYTIOREACTION APPARATUS Leland W. T. Cummin gs, Wyncote, Pa, assignor to Sun Oil Company, Philadelphia, Pa., a corporation of New Jersey Application October 13, 1947, Serial No. 779,558

7 Claims.

This invention relates to improved apparatus for conducting catalytic reactions and more particularly to apparatus for carrying out catalytic processes involving alternate endothermic and exothermic reactions, A typical process of this type is the catalytic conversion of hydrocarbons in a cyclic operation, wherein hydrocarbons are caused to react endothermically in the presence of a catalytic contact mass, causing deposition of carbonaceous deposits on the mass which reduce the catalytic activity, and the catalyst is then reactivated by burning off the carbonaceous material. The catalytic cracking of higher boiling hydrocarbons to lower boiling hydrocarbons is a specific example of this type of process. Other examples are reforming, dehydrogenation and the like.

More specifically, the present invention is concerned with an improved catalytic reactor for use in a stationary bed type of operation, wherein the catalyst is employed in the form of a plurality of stationary beds within the reactor and is regenerated periodically in situ by passing hot oxygen-containing gases through the several beds. The reactor is especially adapted for use in that type of catalytic conversion generally referred to in the art as adiabatic operation. By this is meant that both the endothermic and exothermic reactions are carried out without the use of a circulating convective fluid for supplying heat to, or removing heat from, the reaction zone by indirect heat transfer. In other words, in such adiabatic operation the heat required for the endothermic reaction is supplied either as sensible heat of the reactants entering the reaction zone or as heat stored in the contact mass during the previous regeneration period, while the heat evolved during the exothermic reaction either is stored in the contact mass for use in the subsequent on-stream period or else is removed from the reaction zone in the form of sensible heat of the eiiluent regeneration gases. The reaction apparatus according to the present invention is especially adapted for storage within the contact mass of a large proportion of the exothermic heat evolved during the regeneration period for use during the subsequent on-stream period. A feature of the invention permits the utilization of this stored heat not only as heat of reaction but also as heat for evaporating hydrocarbon charge material introduced between the several beds of catalytic contact mass.

The features and advantages of the invention can best be understood by reference to the accompanying drawings, in which;

Figure 1 is an elevational view, partly in section, of one form of the improved catalytic reactor;

Figure 2 is a top view of the reactor of Figure 1 with sections broken away at several levels to show internal details;

Figure 3 is a sectional view of a portion of the reactor showing a modified catalyst tray arrangement;

Figure 4 is a sectional view of a portion of the reactor showing another modification in tray arrangement;

Figure 5 is a partly sectional View showing another modification in tray arrangement and also showing external means for introducing additional reactants;

Figure 6 is a partly sectional view similar to Figure 5 but representing another modification;

Figure '7 is an enlarged view, partly in section, of the external means for introducing additional reactants; and

Figure 8 is a partly sectioned elevational view of a modified form of the reactor.

It will be understood that the drawings are merely illustrative of certain embodiments and that numerous specific modifications may be made without departing from the scope of the invention.

Referring to the drawings, Figures 1 and 2 show one form of the improved catalytic reaction apparatus wherein the body of the reactor comprises a vertically elongated cylindrical outer shell m and a vertically elongated cylindrical inner shell ll concentrically disposed therein to form an annular space between the shells. Manifold means are provided at both the top and bottom of the reactor for introducing reactants into the annular space at the top and withdrawing reaction products from the annular space at the bottom. As shown in the drawings, such manifold means may comprise a top cover member l2 integrally connected to the inner and outer shells and having one or more inlet connections or nozzles 3 for introduction of reactants, and a bottom member l4 having one or more outlet connections or nozzles l5 for withdrawing the reaction products.

Located within the annular space between the inner and outer shells are a plurality of superposed trays, shown generally as IS, IT, I 8 and it, which are positioned in spaced apart relation to each other and are each adapted to retain therein a bed of granular contact material indicated by numerals 21, 28, 29 and 35. While for purpose of illustration four such trays or beds are shown, it will be understood that any suitable or desired number may be provided. Since all the trays may be of similar construction, the following description thereof is made with specific reference only to the top tray. Each tray may comprise an outer wall 20 which is continually perforated to permit flow of fluid therethrough and which hasa diameter less than that of the outer shell It so as to provide an annular space 2| at the outer side of each tray, and an inner wall 22 which is likewise perforated and which has a diameter greater than that of the inner shell ll so as to provide an annular space 23 at the inner side of the tray. Arr imperforate top member 26 covers the top of each tray and carries on the side adjacent the inner shell H a shoulder portion 25 which eggtends inwardly to the inner shell, thereby closing off the top of annular space 23. The shoulder portion 25 preferably should include an expansion joint (not shown) to provide for expansion or contraction resulting from temperature changes during use of the apparatus.

' Each tray also comprises an imperforate bottom plate member 25 which extends laterally from inner wall 22 to outer shell l0, thereby functioning as a bottom for the tray and also serving to close the outer annular space 2i at its bottom. The trays may be supported within the apparatus by means of a plurality of beams 31' extending radially from the outer shell ID to the inner shell H and resting upon support means 32 and 33 secured to the outer and inner shells, respectively, in any suitable manner. The simplicit 'of construction of the support means for the catalyst trays is a particularly advantageous feature of the present reactor.

The trays are filled witha granular contact material, illustrated in the drawings by numerals 21, 28, 29 and 36, which preferably is a mixture of catalyst (for example, a silica-alumina type catalyst if the reaction'to be conducted is the cracking of hydrocarbons) and a granular inert material of high heat absorbing capacity (for example, artificially fused oxide such as described in Houdry Patent No. 2,414,812). The proportion of catalyst to heat absorbing material may vary widely depending upon the particular materials used and the amount of heat that it is desired to store'in the contact mass during each cycle, but generally will be within the range of 1:5 to 3:1. With the tray construction as shown in Figure 1 and with the general direction of reactant flow from top to bottom of the reactor, it will be apparent that the flow of reactants through each bed will be in a generally horizontal direction inwardly. Thus, reactants will enter each bed from the outer annular space 21 through the perforations'in'outer wall 20 and will leave each bed b issuing through the perforations in inner wall 22 into the inner annular space 23, thence flowing to the next lower'bed and passing therethrough in like manner.

It is distinctly preferable that each of the walls, 20 and 22, be so designed with respect 'to the number and size of perforations that the pressure drop across each wall during regeneration will be within the range of 0.2 to 1.0 lb./sq. in; and preferably of the order of 0.5 lb./sq. in. This will insure good distribution of regenerat ing gas flowing through the contact mass and will minimize by-passing in' case of shrinkage of the contact mass within the tray. Such shrinkage has been found to occur almost in-- variably upon prolonged operation, and'consequently it is of great importance that the inner and outer walls of the trays be properly orificed to give the desired pressur drop as above specified for the regeneration period. This will also insure satisfactory distribution of reactants during the on-strearn period.

In the space between adjacent beds of catalytic contact material, means are provided for introducing additional amounts of reactants in the form of a fine spray into the vapor stream passing from one bed to the next lower bed. Figures 1 and 2 show such means for introducing liquid reactants, for example, between the uppermost tray l6 and the next lower tray [1 as a plurality of inlet lines 34 leading from a circular manifoldline'35 into the reactor and each having a liquid spray nozzle 36 preferably pointing upwardly. Similar arrangements are provided for introducing liquid reactants from feed lines 31 and 38 into the spaces between the other trays It will be noted that the catalyst beds l6, I1, I 8 and I9 are of varying height, increasing in the direction from top to bottom of the reactor. This is distinctly preferable in order to compensate for the additional reactants introduced as spray between the beds so that the space velocities of reactantspassing through the severa1 catalyst beds will be about the same. In operation, during .the on-stream or endothermic reaction period, hydrocarbon reactants are introduced into the top of the reactor through inlets l3 and pass into the outer annular space 2| and inwardly through the uppermost catalyst bed 16 and into the inner annular space 23. In passing through bed IS the reactants will absorb heat, from the contact material 21 in excess of that necessary for the endothermic conversion reaction and accordingly the hydrocarbons flowing into inner annular space 23 will be at a higher temperature than the reactants entering bed 16. The temperature will also be higher. at this point than desired for reaction in the next lower catalytic bed I1. This excess heat in the reactants from bed I6 is utilized to vaporize the liquid reactants injected through lines 34 and spray nozzles 36 so that the temperature of the mixture passing to bed 11 will be at the desired value. The resulting vapor mixture then passes through bed I! where heat is again picked up in excess of that necessary for maintaining the catalytic conversion reaction, and after passing through the bed the vapors commingle with the next liquid spray introduced through the spray nozzles positioned between beds l1 and 18. Liquid reactants are injected at this point again in sufficient amount to reduce the temperature of the mixture pass ing to bed l8 to the desired value. The mixture then flows through bed 18 where absorption of heat is again in excess of that necessary for the reaction, and the resulting reactants are again cooled after leaving bed 15 by admixture with a third liquid spray introduced through the lowermost set of spray nozzles before passing to catalytic bed I9, etc.

By way of example, in the catalytic cracking of hydrocarbons the reactants flowing to bed It may have a temperature of say 800-900 15 whereas the hydrocarbons issuing from bed l6 into inner annular space 23 may have a temperature of 1000 1100 F. Suflicient liquid reactants, at a temperature of say 200-600 F., may be introduced as quenching material through spray nozzles 36 to cause'the resulting vapor mixture passing to bed I'! to have'a temperature of 800-900 F. Upon passing through bed I1, the mixture Will absorb sufficient heat to reach a temperature again of 1000-1100 F. Similar fluctuations in temperature will occur as the reactants pass downwardly through the reactor and alternately come in contact with the spray streams and the other catalytic contact masses.

Regeneration of the contact mass is effected by blowing an oxygen-containing gas such as air through the beds. This may be done by passing the regenerated gas through the several beds in series. This method of regeneration, however, may entail certain disadvantages. A possible disadvantage is that upon completing the regeneration in this manner the beds may be left at difierent temperatures, the first bed tending to have a temperature about the same as that of the entering regeneration gas whereas the last bed may be at a considerably higher temperature. When this condition occurs, there will be a\tendency during the subsequent on-stream operation to deposit a greater amount of carbonaceous material in the bed or beds having the higher temperature. Then, upon further regeneration, the temperature of these beds may become even higher than during the previous regeneration. Thus, it is possible that regeneration in series may result in overheating of certain beds. A still further disadvantage of this type of regeneration is that it necessitates a high pressure drop through the reactor.

In order to permit the regeneration to be carried out in improved manner, the reactor is provided with side inlet or outlet means between the beds, illustrated in Figure 1 as flanged nozzles 39, cc and 4!. Nozzles 39 and 4| serve as inlets for the regenerating gas while nozzle 40 and nozzles l3 and i5 serve as outlets for the combustion gases. During regeneration, regenerating gas enters through inlet nozzle 39 into the space between beds Ii: and I1 and thence flows in two directions. One portion flows through bed 56 and out of the reactor at the top through nozzles l3. The rest of the regenerating gas passes downwardly through bed I! and out of the reactor through nozzle 40. In view of the construction of the beds, the flow of regenerating gas therethrough is automatically maintained at the same space velocities and no additional means is needed for regulating the relative rates of flow to the individual beds. Regenerating gas is likewise introduced through nozzle 4 l' into the space between beds l8 and I9, whence part of it flows through bed l8 and out of the reactor through nozzle 40 while the rest passes downwardly through bed I9 and outthrough nozzles I 5. By operating in this manner, each bed is regenerated by a separate stream of the regenerating gas, with the result that the temperature of the beds at the end of the regeneration period is more nearly uniform and the pressure drop through the reactor during regeneration is greatly reduced.

Figure 3 illustrates a modified form of catalyst tray arrangement in which the reactants flow across each bed in an outward direction rather than inwardly as in Figure 1. In this modification each tray has an imperforate top member 44 which extends from the inner perforate wall 22--a, to the outer shell Ill-a so as to close the outer annular space 2|a at its top, and an imperforate bottom member 45 which extends from the outer perforate wall Zl'l-a inwardly to the inner shell ll-a. Liquid reactants are introduced between the beds by means of inlet line 34a and spray nozzle 36-12.

Figure 4 shows another tray arrangement wherein the reactants flow through adjacent beds in opposite directions. This has the advantage of minimizing differential expansion of the inner and outer shells, since it eliminates the condition whereby one or the other of the shells is exposed exclusively to the hot efliuent products from the beds before the same are quenched. As shown in Figure 4, the trays alternate in construction between that of Figure 1 and that of Figure 3. Thus, the upper tray may have an imperforate top member 24-12 which extends from outer perforate wall 20-1) to inner shell I l-b to close off the inner annular space 23- 1) at its top, and an imperforate bottom member 26b extending from inner perforate wall 22--b to the outer shell I0b to close off the bottom of outer annular space lit-b. Through this bed, the flow of reactants will be inwardly. The next lower tray will have an imperforate top member 46 which extends outwardly to the outer shell I0b and an imperiorate bottom member 41 extending inwardly to the inner shell l |-b. The flow through this bed will thus be in an outward direction. A baffle 48 is positioned horizontally between the beds to prevent the reactants from flowing directly from one bed to the next, and spray means comprising inlet line 34b and horizontal spray nozzle 49 are provided for injecting liquid spray into the vapor stream passing around the bafile.

Figures 5 and 6 are directed to modifications in which the spray means are located outside of the outer shell of the reactor and in which separating means are provided for removing any liquid which has not vaporized from the Vaporous reactants before the latter are introduced into the reactor and pass to the next catalyst bed. One advantage of these modifications is that the reactor is not subjected to differential temperature effects resulting from contact of the relatively colder liquid spray with portions of the reactor. In Figure 5 the uppermost tray has the same construction as the top tray of Figure 1. Reactants from the top of the reactor flow into outer annular space 2I-c and through the bed into inner annular space 23c. From there, the vapors flow beneath the bed and through the outer shell into conduit 50. Conduit 50 serves also as a spray chamber, the liquid being introduced therein through line 5| and spray nozzle 52 positioned within the conduit. The mixture of reactants flow to a tangential type separator 53 wherein they are introduced essentially tangentially to cause any liquid which is too high boiling to vaporize under the prevailing temperature and pressure conditions to separate from the vapors. Such liquid may be withdrawn from the separator through line 54. The liquid-free vapor then passes through conduit 55 into the outer annular space 56 adjacent the next catalyst bed. Similar externally positioned conduit, spray and separating means are provided for the reactants flowing between the other beds. In order to properly direct the flow, each tray except the top one has an imperforate top member, such as shown at 51, which extends across the entire annular space between the inner and outer shells thereby requiring that the reactants flow through the conduit means outside of the reactor. It is evident that the tangential separator 53 may be omitted in cases where the liquid reactants sprayed into conduit 59 are substantially completely vaporizable under the prevailing temperature and pressure conditions.

, Figure 6 shows an a rangement s m lar toF inc except that lthe flow across each bed is .in an outward direction. 'ilhis is effected, .as shown in Figure :6, by :havingithe toplimperforate :member for each'tray extend from 'the inner perforate wall of the tray to the outer: shell, while .the bottom imperforate member extends entirely across the annular space between the inner and-outer shells, except in the case of the lowermost tray (not shown) 'The.conduit,aspray.and separating means of Figure:fiiinaybelidentical withithat of Figure5, and areshown inrmore detail inFigure '7. Means are includedinFigurex'l forpermittin the spray nozzle- 52 to be removed and cleaned or a new nozzle substituted while the reactor is in operation. .Thislmay comprise arelatively short section of vpipingsconnecting with conduit 50 and having an internaldiameter sufliciently large that spray :nozzle 52 on inlet 5! may pass therethrough. The piping includes a bushing 60 through which :line 5| .is:S1idable,.a:flangecl portionaBLand gatevalve62. Wheneverit-is desired to inspectspray nczzle52 or removeit'from conduit :50 for any :reason, line Til is drawn to the left throug'habushing 160 until spraynozzle-SZ has passed through valve 62. The latter is then closed and the-pipingisopened atiflange' 6 I thereby :permitting access to the spray nozzle.

The reactor :shown in Figure 8 is similar to thatof Figurelexceptthat the manifold means providing a fluid .inlet .to .thezannular space between the inner and outer shells of :the reactor at the :top is different. In this modification the outer shell .includes 'a :convex topportion 64 :carrying inlet nozzle.l3--e, and the inner shellilikewise includes a convex ,top portion 65 which is completely enclosed by the outer shell to provide a .space forlflowof reactants therebetween. Suitable means for supporting the inner shell iinits position within the outer shell should be provided to offset thezpressure-on the top portion BS. The catalyst beds and spray means may be arranged according to any :of the forms above described.

It will be understood that in the above description various details of construction representing good engineering practice have been omitted, since they will be readilyapparent to-one skilled in the art. For instance, it is apparent that suitable manholes should be provided for access-to'the inside of the reactor-andthatmeans should be provided for 'filling and emptying the trays with contact materials. Likewise, suitable insulating means should be included.

Having described my :invention, what I claim and desire to rprotectby Letters Patent is:

1. Catalytic reaction apparatus for conducting alternate endothermic and exothermic reactions Whichrcomprises a vertically elongated outer shell, a vertically elongated .inner shell disposed centra'lly'within saidouter shelltoiorm'an annular space therebetween, manifold means at the top of said annular space providing a fluid-inlet for introductionof reactants, manifold means'at the bottom of said annular space providing a fluid outlet .for'removal of reactionproducts, a=plurality of annular shapedtrays superposed withinsaid annularspace in spaced-apart relation to each other andadaptedeaoh to-retain a bed of granular contact material,- each of said trays comprising an outer perforate wall of lesser "diameter than said outer shell so as to provide'an annular space at the outer-side of the tray and-an inner periorate wall of greater diameter than said inner-shell so as to provide an annular space at the inner side of the tray, an 'imperiorate top imperiorate bottomlmemberfoneaclrof said'trays, means ofor directing lthe :fiow :of .reactants so as to causezthelreactantsito enterleachzbed from-one of :the side annular spaces and :to how therethroughzin a generally horizontal'direction to :the other side annular :space (and "thence to the :inlet side annular spacesadjacent-the next, lower tray andspray means positioned in the ;path of flow -betweenirays for introduction of liquid reactants intoathe fiowingstream inthe'formrof a fine spray.

.2. .Apparatus according to claim 1 .wherein said means for directing the flow of reactants includesra spray chamber .locatedoutside; saidzouter shell .and'withinxwhich'said. spray means is rpositioned, .conduit means sfor passing reactants lfrom said :other side annular space .to 'thesprayichamher and other-.conduitmeans.forpassingrreactants fromthe spray chamber to said inlet side annular space adjacent the next lowertray.

Apparatus according to'claim .1 wherein said means ltor directing the nlow -'of reactants inciud .a spray'chamberllocated: outside said outer shell andiwithin'which'said spray means-ispositioned, conduit meanszforzpassing reactants rfrom said: otherasidesannular :space to I the spray :chamher, a tangential .typeseparator having a vapor outlet at :the :top and 'a liquid outlet :at the bottom, conduitimeansior passing reactants'ifrom said spray chamber .to said separator and introducing the same therein :tangentially at a .locus between. said vapor outlet and said liquid outlet, and conduit .nieans for :passing :the vapor from said separator 'to said inlet side :annular .space adj scent the nextslower :tray.

l. icatalytic reaction apparatus dor 'conducting alternate endothermic land exothermic-reactions which comprises1a?verticallyelongatedaouter shell, a vertically elongated inner shell disposed centrally within said outer shell 130. formzan. annular space 'therebetween, :manifold' means 'at the .top ofrsaid annular space :providing .:a fluid-inlet for introductionnof reactants, manifold :means :at the bottom of said annular space zproviding a ifluid outlet for removal of reaction products, La plurality of -.annul ar. shaped trays superposed within said annular :space spaced-apart irelationito ach other and adapted Leach .toc'retain a bed 'of granular contactl'material, eachoisaid trays comarising an: outer pei forate wall of lesser diameter than said outer shell so as to provide an annular space at the outer side of the tray and :aniinner perforate wall of greater" diameter'than saidinner shell so as to provideean annular space at the inner side of the traman imperforate top memher 7 and an irnperiorate bottom member for: each of said trays, one 0f said imperforate :members extending inwardly to said inner shell 'and the other of said imperforate members extending laterally to --said:outer shell so as.'-tocause the reactants to enter each bed from oneo'f the side annular spaces=and fiow'therethrough in a generally horizontal direction to 'the vothers'i'de -annular spaca'means defining a flow passagewayifrom the outlet-side annularspace adjacent'eachtray 'to the inlet side-annular space adjacent the next lower tray, and spray means positioned in each of said passageways for introduction 'of liquid reactants irito the flowing stream in the form of a fine-spray.

5. Apparatus accordingto-claim 4wherin said means defining-a flowrpassageway includes a-spray chamber located outside said outer shell and within which said spray means is positioned, conduit 'means for passing reactants from said member n 'an last-named side annular spacetothe-spray chamher and other conduit means for passing reactants from the spray chamber to said inlet side annular space adjacent the nelxt lower tray.

6. Apparatus according to claim 4 wherein said means defining a flow passageway includes a spray chamber located outside said outer shell and within which said spray means is positioned, conduit means for passing reactants from said last-named side annular space to the spray chamber, a tangential type separator having a vapor outlet at the top and a liquid outlet at the bottom, conduit means for passing reactants from said spray chamber to said separator and introducing the same therein tangentially at a locus between said vapor outlet and said liquid outlet, and conduit means for passing the vapor from said separator to said inlet side annular space adjacent the next lower tray.

7. In combination with a catalytic conversion apparatus adapted for conducting alternate endothermic and exothermic reactions and comprising an outer shell and means within said outer shell for maintaining a series of spaced-apart beds of catalytic contact material; a spray chamber located outside of said outer shell for each pair of adjacent beds of catalytic contact material, spray means positioned within each of said chambers for introducing liquid reactants therein in the form of a fine spray, manifold means for directing the stream of vapors passing from each bed without said outer shell and to the corresponding spray chamber, a tangential type separator in association with each spray chamber and having a vapor outlet at the top and a liquid outlet at the bottom, conduit means for passing the reactants from each of said spray chambers to the corresponding separator and introducing the same therein tangentially at a locus between said vapor outlet and said liquid outlet, and manifold means for directing the stream of vapors from said vapor outlet of the separator to the next bed of catalytic contact material.

LELAND W. T. CUMMINGS.

No references cited 

